FuseAlloy versus Bulk weld overlay

25 September 2015

The harder the steel, the greater the wear resistance, right? While this may be technically true, you only need to look at chromium carbide plate to see that hardness isn’t the only criteria for wear resistance.

Chromium carbide overlay plate is used for severe abrasion applications, such as trucks, dozer and bucket liners, wear plates, chute liners, screed plates and hopper liners. As the name hints, it consists of a mild steel base plate with a highly abrasion-resistant overlay.

Consumers often assume that all chromium carbide plate is the same. However, different manufacture methods can produce microstructures and finishes that vary considerably.

In this article we look at two types of chromium carbide overlay plate – bulk weld overlay vs FuseAlloy smooth surface overlay – and discuss how two products with roughly the same hardness (55-63 HRC) can vary greatly in appearance, composition and, perhaps more crucially, wear resistance properties.

Bulk weld overlay

Bulk weld overlay plate has a rough surface finish with multiple surface relief cracks. It has a distinct weld bead pattern, which when combined with the rough finish and surface cracks can cause hang-up problems where material builds up on the surface.

From a technical perspective, a cross-section of this type of plate shows high dilution, with an uneven seam between the backing plate and the overlay. This unevenness contributes to an accelerated wear rate as the overlay thickness starts to reduce.

Finally, bulk weld overlay tends to offer poor rolling and fabrication due to the high residual stress between the backing plate and the overlay.

FuseAlloy smooth surface overlay

In contrast, FuseAlloy’s unique manufacturing process provides a smooth surface finish with low friction and excellent abrasion resistance properties. It produces no weld beads, minimal surface relief cracks and a low dilution with a uniform seam between the backing plate and the hardface overlay.

Unlike bulk weld overlay plates, FuseAlloy offers consistent hardness and predictable wear rates. Its smooth finish means there’s less friction and reduced hang-up. Also, FuseAlloy is easily rolled and worked due to the low residual stress between the backing plate and overlay.

Need help choosing the right wear plate?

For more general information on wear plates, or for specific advice on whether FuseAlloy or bulk weld overlay plate is suited to your requirements, the ShapeCUT team can help.